Flyback converter

ABSTRACT

The flyback converter generally has a capacitive divider operatively connectable to a voltage source for receiving an input voltage, the capacitive divider having a plurality of capacitive devices connected in series from one another; a transformer having a plurality of primary windings inductively coupled to at least one secondary winding, each one of the primary windings of the transformer being connected in parallel to a corresponding one of the capacitive devices of the capacitive divider via a switching device, each of the at least one secondary winding being connected to a forwardly biased and capacitive circuit connectable to an output load; and a controller connected to each one of the switching devices for operating the flyback converter to power the output load with the voltage source.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a continuation of U.S. Non-Provisional applicationSer. No. 15/539,431, filed Jun. 23, 2017, which claims the benefit ofpriority to International Application PCT/CA2015/000587, filed Nov. 30,2015, which claims the benefit of priority under 35 U.S.C. § 119(e) toU.S. Provisional Application No. 62/096,322, filed Dec. 23, 2014, all ofwhich are incorporated by reference herein in their entirety.

FIELD

The improvements generally relate to the field of switch-mode powersupplies, and more particularly to the field of flyback converters usedfor providing direct current (DC) from alternating current (AC) or DCvoltage sources.

BACKGROUND

Switch-mode power supplies (SMPSs) converting alternating current (AC)to direct current (DC) and/or DC to DC are widely spread in the consumerelectronics market. These SMPSs typically provide regulated power toportable and/or stationary electronic devices consuming from severalwatts up to several hundreds of watts. Among the SMPSs available,flyback converters are appreciated for their enhanced robustnessassociated with a galvanic isolation between the input and the output ofthe flyback converter.

Although the conventional flyback converter have many advantages overother types of SMPSs, when the input voltage source has a relativelyhigh voltage, greater restrictions are imposed on the flyback convertercomponents, namely on the voltage switch and the transformer, whichtended to limit the use of flyback converter topologies. There thusremained room for improvement.

SUMMARY

There is provided a flyback converter involving a transformer having aplurality of primary windings where each of the primary windings isconnected in parallel with a corresponding one of a plurality ofcapacitive devices. These capacitive devices are provided in the form ofa capacitive divider which receives an input voltage from a voltagesource. The capacitive divider then divides the input voltage into aplurality of smaller, divided voltages which are provided to each one ofthe capacitive devices and thus, to the primary windings connectedthereto. By dividing the input voltage into a plurality of capacitivedevices, the restrictions imposed on each one of the associated switchescan be significantly reduced, allowing the use of a plurality ofcommoditized switches such as metal-oxide-semiconductor field-effecttransistors (MOSFETs), for instance, instead of a single higher-voltageswitch.

In accordance with one aspect, there is provided a flyback convertercomprising: a capacitive divider operatively connectable to a voltagesource for receiving an input voltage, the capacitive divider having aplurality of capacitive devices connected in series from one another; atransformer having a plurality of primary windings inductively coupledto at least one secondary winding, each one of the primary windings ofthe transformer being connected in parallel to a corresponding one ofthe capacitive devices of the capacitive divider via a switching device,each of the at least one secondary winding being connected to aforwardly biased and capacitive circuit connectable to an output load;and a controller connected to each one of the switching devices foroperating the flyback converter to power the output load with thevoltage source.

In accordance with another aspect, there is provided a method foroperating a flyback converter including a transformer having a pluralityof primary windings each being connected in parallel with acorresponding capacitive device of a capacitive divider, the methodcomprising the steps of: providing an input voltage to the capacitivedivider; successively and repeatedly operating each one of the primarywindings using a portion of the input voltage via the correspondingcapacitive device; and generating an output voltage to an output load ofthe flyback converter upon said operation.

In accordance with another aspect, there is provided a flyback convertercomprising: a capacitive divider operatively connectable to a voltagesource for receiving an input voltage, the capacitive divider having aplurality of capacitive devices connected in series from one another toproduce a voltage drop across each one of the capacitive devices; atransformer with a plurality of primary transformer windings, and asecondary output winding; a plurality of switches each for selectivelyinterconnecting one of the primary transformer windings with one of thecapacitive devices to drive a load connected with the output winding; acontrol circuit for operating the switches based on current at theswitches.

Many further features and combinations thereof concerning the presentimprovements will appear to those skilled in the art following a readingof the instant disclosure.

DESCRIPTION OF THE FIGURES

In the figures,

FIG. 1 is a schematic diagram of an example of a flyback converter, inaccordance with an embodiment;

FIG. 2 is a schematic diagram of an example of a flyback converter forconverting alternating current (AC) to direct current (DC), inaccordance with an embodiment;

FIG. 3 is a schematic diagram of an example of a flyback converter forconverting DC to DC, in accordance with an embodiment;

FIG. 4 is a schematic diagram of an example of a flyback converter forconverting DC to DC, in accordance with an embodiment;

FIG. 5A is a graph of an exemplary curve showing a normalizedtransformer volume and magnetizing inductance value (L_(m)) as afunction of a number of primary windings of a transformer;

FIG. 5B is a graph of an exemplary curve showing a normalized switchloss as a function of a number of primary windings of a transformer;

FIG. 5C is a graph of an exemplary curve showing a normalized conductionloss as a function of a number of primary windings of a transformer;

FIG. 5D is a graph of an exemplary curve showing a normalized peak inputcurrent as a function of a number of primary windings of a transformer;

FIG. 6 is a schematic diagram of an example of a transformer of aflyback converter, in accordance with an embodiment;

FIG. 7 is a schematic diagram of an example of a flyback converter, inaccordance with an embodiment;

FIG. 8A is a graph showing the evolution of an input voltage, an inputcurrent and an output voltage as a function of time for the conventionalflyback converter;

FIG. 8B is a graph showing the evolution of an input voltage, an inputcurrent and an output voltage as a function of time for the flybackconverter of FIG. 6, in accordance with an embodiment;

FIG. 9A is a graph showing the evolution of a normalized switch gatevoltage, a magnetizing inductance current, a switch voltage and a switchcurrent for the conventional flyback converter;

FIG. 9B is a graph showing the evolution of a normalized switch gatevoltage, a magnetizing inductance current, a switch voltage and a switchcurrent for the flyback converter of FIG. 7, in accordance with anembodiment;

FIG. 10A is a graph showing a magnitude associated with input currentharmonics for the conventional flyback converter;

FIG. 10B is a graph showing a magnitude associated with input currentharmonics for the flyback converter of FIG. 6, in accordance with anembodiment;

FIG. 11 is a graph showing the evolution of input voltages, switchcurrents, magnetizing inductance current and output voltage as afunction of time for a flyback converter, in accordance with anembodiment; and

FIG. 12 is a graph showing a balancing phase and a balanced phase of theinput voltages as a function of time, in accordance with an embodiment;and

FIG. 13 is a schematic diagram of an example of a flyback converterutilizing a bus capacitor, 123, and sense resistor, 180, for currentsensing, in accordance with an embodiment.

FIG. 14 is a schematic diagram of an equivalent circuit of a flybackconverter with current sensing, ie. FIG. 13, in accordance with anembodiment

FIG. 15 is a graph showing the sensed current, i.e. the input currentand switch current waveforms, of a simulated embodiment of FIG. 13.

These drawings depict exemplary embodiments for illustrative purposes,and variations, alternative configurations, alternative components andmodifications may be made to these exemplary embodiments.

DETAILED DESCRIPTION

FIG. 1 shows an example of a flyback converter 100, in accordance withan embodiment. As depicted, the flyback converter 100 has a voltagesource 110 powering the flyback converter 100 with an input voltage Vin.The input voltage can be provided either as an alternating current (AC)or as a direct current (DC), as will be detailed further hereinbelow.The voltage source 110 is connected to a capacitive divider 120 whichhas a plurality of capacitive devices 122 connected in series from oneanother for receiving the input voltage Vin. Each one of the capacitivedevices 122 has a capacitance value Ck associated thereto, wherein i isa positive integer associated with a corresponding one of the capacitivedevices 122. Along the capacitive divider 120, each one of thecapacitive devices 122 receives a smaller, divided voltage Vin′,k. Theflyback converter 100 has a transformer 130 connected to the capacitivedivider 120. More specifically, the transformer 130 has a plurality ofprimary windings 132 inductively coupled to at least one secondarywinding 134. The secondary winding 134 is, in turn, connected to aforwardly biased and capacitive circuit 140 in order to provide anoutput voltage Vout to an output load 150.

Moreover, the flyback converter 100 has a plurality of switching devices160 connected to each one of the primary windings 132 of the transformer130. Each one of the switching devices 160 are operatively controlled bya controller 170 for operating the flyback converter successively andrepeatedly in on- and off-states during normal use of the flybackconverter 100. During normal use of the flyback converter 100, only oneswitching device 160 is operated at a time, enabling distribution of thepower losses over all input stage components and minimization of hotspots, thus reducing cooling requirements. Specifically, the flybackconverter 100 is configured to provide the input voltage Vin to thecapacitive divider 120; to successively and repeatedly operate, usingthe switching devices 160, each one of the primary windings 132 using aportion of the input voltage Vin via the corresponding capacitive device122 in order to generate the output voltage Vout to the output load 150of the flyback converter 100 upon said operation. It is noted that theoperation of the switching device during use of the flyback converter100 can be performed in any sequential or logical order, for instance.

When one of the switching devices 160 is operated (e.g. closed), thetransformer is characterized by a magnetizing inductance value Lm. Themagnetizing inductance value Lm may vary depending of which of theswitching devices 160 is closed. The switching devices 160 are generallyprovided in the form of metal-oxide-semiconductor field-effecttransistors (MOSFETs) which can manage the smaller, divider voltagesVin′,k.

The forwardly biased and capacitive circuit 140 generally has at least abiasing device 142 typically provided in the form of a diode and anoutput capacitive device 144. During normal use, the flyback converteris adapted to, when operated in the on-state, store energy in a magneticcore 132 of the transformer 130 and then to, when operated in theoff-state, deliver the stored energy to both the output capacitivedevice 144 and the output load 150 via the secondary winding 134. As thecapacitive device 144 stores energy from the magnetic core via thesecondary winding 134 when operated in the off-state, the flybackconverter 100 is also adapted to deliver this stored energy to theoutput load 150 when it is subsequently operated in the on-state. Atthis stage, the biasing device 142 helps direct the energy to the outputload 150.

In another embodiment, the number of primary windings, i.e. inductancevalues Lm, differ from a primary winding 132 to another, so that thesmaller, divided voltages Vin′,k also differ. Typical capacitive valuescan span from nF to mF range while typical inductance values can spanfrom nH to mH.

The flyback converter 100 can i) reduce the magnitude of the inputvoltage seen by each individual primary windings 132; ii) reduce thepeak magnitude and lower the frequency harmonics of the input current;iii) distribute the input power losses over the multiple primarywindings 132 and switching devices 160; iv) achieve passive inputcapacitor voltage balancing; and v) allow for the use of a singlesnubber, clamp or soft-switching device 230 to one of the primary and/orsecondary windings 132 of the transformer 130.

FIG. 2 is another example of the flyback converter 100 for convertingalternating current (AC) to direct current (DC). As shown, the flybackconverter 100 has the voltage source 110 which is adapted, in thisexample, to provide AC. This specific embodiment has a k number ofprimary windings 132 and associated capacitive devices 122 and switchingdevices 160. The flyback converter 100 has an input filter 210operatively connected to the voltage source 110 for providing a filteredinput voltage either directly or indirectly to the capacitive divider120. In this specific embodiment, the input filter 210 is indirectlyconnected to the capacitive divider 120 via a rectifier device 220. Therectifier device is generally provided in the form of a diode rectifierin order to rectify the AC provided by the input source 110. Moreover,in this embodiment, a snubber device 230 is provided for reducing aleakage voltage of the flyback converter 100. It is noted that thesnubber device 230 is connected to one of the primary windings 132.

FIG. 3 is another example of the flyback converter 100 for converting DCto DC. In this specific embodiment, the voltage source 110 is adapted toprovide a direct current (DC) to the flyback converter 100. The flybackconverter 100 has the input filter 210 to filter the input voltage Vinprovided by the voltage source 110.

FIG. 4 is another example of the flyback converter 100 for converting DCto DC. As illustrated, the voltage source 110 is provided in the form ofa plurality of batteries 410 connected in series from one another,wherein each one of the capacitive devices 122 of the capacitive divider120 corresponds to a corresponding one of the plurality of batteries410.

Due to the smaller, divided input voltages Vin′,k, the volume of thetransformer 130 of the flyback converter 100 and its power efficiencycan be optimized. More specifically, the volume of the transformer 130can be minimized and the use of “low-voltage” switching devices 160 isallowed. Typically, such low-voltage switching devices 160 can bemetal-oxide field effect transistors (MOSFETs), bipolar junctiontransistors (BJTs), and/or insulated-gate bipolar transistor (IGBTs).The reduced volume of the transformer 130 tends to significantly reducethe volume of the associated flyback converter 100. Moreover,low-voltage MOSFETs 160 are desirable due to their lower switchinglosses, lower conduction losses and lower cost.

As a result of the reduced magnitude of the peak input current and ofthe elimination of low-frequency harmonic components, a corner frequencyof the electromagnetic interference (EMI) input filter 210 can beincreased. Therefore, the volume of reactive components of the EMIfilter 210 can be minimized, contributing to further reducing theoverall volume of the flyback converter 100.

Due to the topology of the flyback converter 100, passive inputcapacitor voltage balancing can be obtained. Indeed, when a relativelysmall capacitor voltage misbalance condition occurs, one or more bodydiodes of the MOSFETs 160 can become forward biased, thus enablingelectric charge to be redistributed from the capacitive device 122 (orthe battery 410) with the largest voltage to other capacitive devices122 (or other batteries 410) with lower voltages. The equivalent circuitformed during the charge distribution is an LC type, consisting of theinput capacitances and leakage inductances which greatly limits the peakcurrent magnitude. As a result, a maximum passive operation inputvoltage misbalance, less than the forward voltage of the body diode ofthe MOSFET 160 (<1.2 volts usually), can be obtained.

It is noted that the configuration of the transformer 130 allows for theuse of a single snubber device 230, generally provided in the form of apassive residual-current device (RCD) or an active clamp snubber, whichcan reduce the number of components, its complexity and also its cost.

The following paragraphs present some graphs detailing the volume andpower processing loss reductions using an AC-to-DC power factorcorrection (PFC) of the flyback converter 100 operating in criticalconduction mode, for instance.

For AC-to-DC PFC applications, utilizing constant ton control, thevolume VL of the transformer 130 can be given by:

$\begin{matrix}{{V_{L} = {{\frac{1}{2} \cdot L_{m} \cdot I_{peak}^{2} \cdot \rho_{L}} = {\frac{\pi}{2} \cdot P_{load} \cdot t_{on} \cdot \left( {1 + \frac{V_{p}}{n \cdot k \cdot V_{out}}} \right) \cdot \rho_{L}}}};} & (1)\end{matrix}$

where Lm is the magnetizing inductance value, Ipeak is the peakmagnetizing current, Pload is the maximum load power, ton is the on-timeof each primary side MOSFET 160, Vp is the peak input voltage, k is thenumber of primary windings 132, n is the transformer conversion ratio,ρL is the inductor energy density and Vout is the output voltage. FIG.5A is a graph of an exemplary curve showing a normalized inductancevolume as a function of the number k of primary windings 132 of thetransformer 130. Referring to FIG. 5A, it can be seen that the volume ofthe transformer 130 and the magnetizing inductance value can be reducedwhen using a flyback converter 100 having a plurality of primarywindings 132, when computed using values associated with typicaloperating conditions, e.g. Vp=155V, Vout=12V, n=3, ton=constant,Pload=100 W, ρL=constant, and Ron=constant).

As will be described, the on-resistance, Ron, and gate channel charge,Qg, of a MOSFET 160 are two performance metrics which can be used forrepresenting the MOSFET 160 conduction and switching losses,respectively. The product of these two metrics can be referred to as afigure-of-merit (FOM). The FOM for the flyback converter 100 can begiven by:

$\begin{matrix}{{{FOM} = {{{Q_{g} \cdot R_{on}} \propto V_{ds}^{\beta}} = \left( {\frac{V_{p}}{k} + {n \cdot V_{out}}} \right)^{\beta}}};} & (2)\end{matrix}$

where Vds is the maximum blocking voltage, and β is a process dependantscaling factor (>2 for typical operation of the flyback converter 100).

From equation (2), it can be seen that a substantial reduction of theFOM is achievable through the addition of multiple primary windings 132,thus by increasing k. The effect of the reduction of the gate charge onthe switching losses of the MOSFET 160 can be analyzed with the help ofequation (3), presented hereinbelow, which describes the peak switchingloss for typical AC-to-DC PFC application.

$\begin{matrix}{{{P_{sw}^{p\; k} \approx {K_{1} \cdot \frac{\left( {\frac{V_{p}}{k} + {n \cdot V_{out}}} \right) \cdot \frac{I_{p\; k}}{n} \cdot Q_{g}}{T_{sw}^{{ma}\; x}}}} = {K_{2} \cdot \frac{\frac{V_{p}}{k} + {n \cdot V_{out}}}{t_{on}} \cdot Q_{g}}};} & (3)\end{matrix}$

where K1 and K2 are process dependant constants. FIG. 5B is a graph ofan exemplary curve showing a normalized switch loss as a function of thenumber of the primary windings 132 of the transformer 130 computed fortypical operating conditions of the flyback converter 100, e.g. Vp=155V,Vout=12V, n=3, β=2.64, ton=constant, and PFETon/Ron=constant. Referringto FIG. 5B, it can be seen that the reduction of the peak switching losscan be significant by simply adding a second primary winding 132. Forapplications with dominant switching losses, the reduction of the peakswitching loss can enable a three times increase of the switchingfrequency, which can result in an additional three times reduction ofreactive components (5.5 times total when combined with FIG. 5A).

Moreover, the effect of the reduction of the on-resistance, Ron, on thepeak conduction losses of the MOSFET 160 can be analyzed with the helpof this equation:

$\begin{matrix}{{P_{{FET}_{on}}^{p\; k} = {{I_{{FET}_{{rm}\; s}}^{2} \cdot R_{on}} = {K_{3} \cdot \frac{\frac{V_{p}}{k} + {n \cdot V_{out}}}{\left( \frac{V_{p}}{k} \right)^{2}} \cdot R_{on}}}};} & (4)\end{matrix}$

where K3 is a process dependant constant. In accordance with equation(4), FIG. 5C presents a graph of an exemplary curve showing a normalizedconduction loss as a function of the number of the primary windings 132of the transformer 130 using typical operating conditions, e.g. Vp=155V,Vout=12V, n=3, β=2.64, ton=constant, and Psw/Qg=constant. Referring toFIG. 5C, it can be seen that the reduction of the conduction losses isrelatively constant for greater than two primary windings 132, whichtends to be in the range of 40-50%.

The structure involving the plurality of primary windings 132 of theflyback converter 100 tends to reduce the input voltage linearly as afunction of the number k of primary windings 132. Concurrently, in orderto maintain energy conservation, the input current is amplified. As aresult, the peak input current can be associated with an attenuatedversion of the magnetizing current, which can be given by:

$\begin{matrix}{{I_{i\; n}^{p\; k} = {{\frac{1}{k} \cdot I_{L_{m}}^{p\; k}} = {\frac{\pi \cdot P_{load}}{n \cdot V_{out}}\left( {\frac{1}{k} + \frac{n \cdot V_{out}}{V_{p}}} \right)}}};} & (5)\end{matrix}$

Furthermore, the flyback converter 100 can be used to increase theswitching frequency, while achieving lower switching losses, thusallowing the input current energy spectrum to be shifted to higherfrequencies. The combined effect of the lower peak input current andhigher frequency energy spectrum enable the volume of the EMI inputfilter 210 to be significantly reduced. FIG. 5D is a graph of anexemplary curve associated with equation (5) and showing a normalizedpeak input current as a function of the number k of primary windings 132of a transformer 130 with the typical operating conditions. Referring toFIG. 5D, it can be seen that the normalized input current drops whenusing a transformer 130 having more than one primary windings 132 for atypical AC-to-DC PFC application.

As mentioned above, the flyback converter 100 allows for achieving apassive input capacitor voltage balancing. In order to minimize themaximum reverse voltage of the MOSFET 160, eliminate unstable voltagebalancing runaway conditions and maximize the lifespan of batteries 410(if used instead of the capacitive divider 120), it is desirable tomaintain sharing of the voltage of the capacitive devices 122. As perits configuration, the flyback converter 100 tends to share the inputvoltage without requiring additional circuits, for instance.Accordingly, when a relatively large input voltage misbalance occurs,the misbalance can be automatically damped using the flyback converter100 having a plurality of primary windings 132.

FIG. 6 is a schematic diagram of the transformer 130 of the flybackconverter 100 in order to illustrate how the balancing works. Asdepicted, the transformer 130 has first and second primary windings632A, 632B, first and second capacitive devices 622A, 622B and first andsecond switching devices 660A, 660B. Accordingly, when the differencebetween the input voltage V1 of the first primary winding 632A and theinput voltage V2 of the second primary winding 632B is sufficientlylarge to forward bias the body diode of the second switching device660B, the second primary winding 632B typically begins to conductcurrent. This current flows into the second capacitive device 622B fromthe first capacitive device 622A, thus balancing the voltages. In otherwords, the input capacitor voltage balancing occurs when, for instance,the first switching device 660A is closed so that an electrical link isformed with the first primary winding 632A and to the associatedcapacitive device 622A. In this case, if the voltage V1 of the firstcapacitive device 622A is more than any other voltages of the capacitivedevices, say V2, electrical charges will tend to be transferred from thefirst capacitive device 662A to the second capacitive device 622B viathe transformer 130 and a body diode of the second switching device660B. When the switching devices 660A and 660B are operated successivelyand repeatedly, such a voltage balancing across the first and secondcapacitive devices 622A and 622B can be achieved. It should be notedthat due to the leakage inductance which tends to be present, thecurrent typically has a sinusoidal shape, whose frequency is a functionof the leakage inductance and capacitance values.

As for the snubber device 230, the flyback converter 100 allows energytransfer between the primary windings 132, as per the schematic diagramsdescribed hereinabove. As a result, the single snubber device 230connected to one of the primary windings 132 can clamp thedrain-to-source voltage of the MOSFET 160 by ringing shortly afterdisengagement of MOSFET 160. Furthermore, when the transformer leakageinductances are relatively small, which can be the case. The maximumdrain-to-source voltage values can approximately be the same.

FIGS. 8A-9B present simulations comparing a conventional flybackconverter having a single one primary winding to the flyback converter100 having three primary windings 132, as depicted at FIG. 7. Thesesimulations were processed using PLECS, a widely used simulationsoftware for power electronics. These simulations were performed both toverify the performances of the flyback converter 100 and to theseperformances with the typical flyback converter having a single oneprimary winding. The parameters used for the following are summarized inTable 1.

TABLE 1 Parameters used for the simulations Parameters Value Peak InputVoltage (Vp) 155 V Output Voltage (Vout) 12 V Turns Ratio (n) 3 LoadPower (Pload) 100 W Switching Frequency for the 100 KHz conventionalflyback converter having a single primary winding Switching Frequencyfor the 217 KHz flyback converter 100 having three primary windingsMagnetizing inductance for the 21 μH conventional flyback converterhaving a single primary winding Magnetizing inductance for the 5 μHflyback converter 100 having three primary windings

FIG. 8 show the evolution of the input voltage Vin, the input currentIin and the output voltage Vout as a function of time for theconventional flyback converter having a single primary winding in FIG.8A and for the flyback converter 100 having three primary windings 132in FIG. 8B in a typical AC-to-DC PFC application. As shown, the reducedinput current peak, along with higher effective frequency allowssignificant reduction of the volume of the input filter 210, forinstance, which can significantly reduce the overall volume of theflyback converter.

FIG. 9 show the evolution of the normalized switch gate voltageGate_SW1, the magnetizing inductance current Ilm, the switch voltageVsw1 and a switch current Isw1 for the conventional flyback converterhaving a single primary winding in FIG. 9A and for the flyback converter100 having three primary windings 132 in FIG. 9B in a typical AC-to-DCPFC application.

A comparison of some parameters stems from theses simulations and arepresented in Table 2.

TABLE 2 Comparison of parameters between the conventional flybackconverter and the flyback converter of FIG. 7 Conventional Flybackconverter flyback having three Difference Parameters converter primarywindings [%] Peak Mag. Ind. Current 13.7 A 18.9 A +38 Mag. Ind. Energy1970 mJ 893 mJ −55 RMS Mag. Ind. Current 7.9 A 10.9 A +38 Voltage Ratingof Sw 191 V 87.7 V −54 Norm. FOM (β = 2.64) 1 0.13 −87 Peak Current ofSw 13.7 A 18.9 A +38 RMS Current of Sw 3.4 A 4 A +18

One of the challenges for using the flyback converter 100 for AC-to-DCPFC applications is to meet electromagnetic interference (EMI)requirements. Indeed, flyback converters typically have discontinuousinput currents, thus containing high frequency harmonics which tend tocreate EMI issues. These EMI issues become even more challenging forhigher power applications where higher magnitudes of discontinuous inputcurrents require bulky and expensive input filters to meet the EMIrequirement. Indeed, these requirements often limit the use of flybackconverters for AC-to-DC conversion with PFC application, despite itsconvenient features such as inherent power factor correction indiscontinuous conduction mode of operation. The effective higherswitching frequency and reduced input current magnitude of the flybackconverter 100 having multiple primary windings 132 allows significantreduction of the volume of the input filter 210 compared to conventionalsingle winding flyback converters. Moreover, this can allow extended useof the flyback converter 100 beyond low/medium power levels.

FIG. 10A shows a graph of the magnitude associated with the inputcurrent harmonics for the conventional flyback converter whereas FIG.10B shows a graph of the magnitude associated with the input currentharmonics for the flyback converter 100 having three primary windings132, as depicted in FIG. 7.

Compared to FIG. 10A, FIG. 10B has input current harmonics at higherthan twice the frequency with reduced magnitude. This can allow for thevolume of the input filter 210 to be reduced by a factor of two due tothe corner frequency of the input filter 210 tending to be proportionalto the volume of the input filter 210. Moreover, reduction of switchinglosses shown in FIG. 5B can allow for operation of the flyback converter100 at a higher switching frequency, allowing for further reduction ofthe volume of both the input filter 210 and transformer 130.

The following presents some graphs detailing the input capacitor/voltagecell balancing. Indeed, FIGS. 11 and 12 show graphs of the evolution ofinput voltages Vin1 and Vin2, switch currents i_(FET1) and i_(FET2),magnetizing inductance current i_(Lm) and output voltage Vout as afunction of time for the flyback converter 100. More specifically, FIG.11 shows the input capacitor voltage balancing described above for aflyback converter 100 having two primary windings 132 for converting 110Vrms-to-12 Vdc AC-to-DC while FIG. 12 shows the input capacitor voltagebalancing for the flyback converter 100 having two primary windings 132for converting 100 Vdc-to-4.5 Vdc DC-to-DC. It can be seen from thesefigures that active voltage balancing occurs in both cases.

As can be understood, the examples described above and illustrated areintended to be exemplary only. For instance, as may be readilyunderstood by one skilled in the art, other embodiments of the flybackconverter 100 can have more than one secondary winding. The term “asecondary winding” is thus used to refer to one secondary winding 134 aswell as two, three or more secondary windings 134. These additionalsecondary windings 134 can be provided with associated biasing devices142 and associated output capacitive devices 144 in order to powerassociated output loads 150. These can be useful for providing secondarypower supplies (for example, to power USB devices, 5 V) at low cost. Inaddition, auxiliary windings can exist for other purposes such aspowering up a controller circuit, sensing, storing of additional energy(for meeting hold up requirement). The scope is indicated by theappended claims.

Current Sensing

Flyback converters 100 rely on current sensing of one or more convertercomponents, usually the switch 160 and/or inductive element 134, toregulate the output voltage and/or input current, improve powerprocessing efficiency and to implement safety features (ie. over-currentprotection). Ideally, the number of current sensing circuits is limitedto the bare minimum in order to decrease the bill-of-material, powerlosses and required printed circuit board (PCB) size, i.e. hardwarecomplexity of the SMPS.

One of the challenges for using the embodied flyback converter 100 isthe multitude of switching elements 160 for which a current sensor maybe required, compared to the state-of-the-art single winding 132 andswitch 160 flyback converter 100. In order to reduce the required numberof current sensors to one, and the associated hardware complexity, thecircuit shown in FIG. 13 can be used. It utilizes a small capacitivedevice 123 in parallel with the capacitive divider 120, and a lowresistance current sensing resistor 152 to measure all of the switch 160currents and the input current 210 (DC, FIG. 3)/220 (AC, FIG. 1/2).

By solving the equivalent circuit of FIG. 14, which captures the stateof the flyback converter 100 and current sensor as shown in FIG. 13 atthe moment when the first switch 160 is engaged (closed), it can beshown that the current through the sense resistor 152 is equal to

$\begin{matrix}{{{i_{1}(s)} \approx {\frac{i_{{FET}\; 1}(s)}{\left( {k + \frac{C_{2}}{C_{bus}}} \right)} + \frac{i_{i\; n}(s)}{\left( {1 + {k \cdot \frac{C_{bus}}{C_{2}}}} \right)}}},} & (6)\end{matrix}$

where the first component is a scaled version of the current through theswitch 160, high-frequency component, and the second component is ascaled version of the input current 210/220, low-frequency component.FIG. 15 shows the simulated currents of the circuit in FIG. 13 for thecase where k=2, C_(bus)=0.1 μF and C₂=1 μF, verifying the principle ofoperation and ability of embodied current sensor to measure all switch160 currents and the input currents 210 (DC, FIG. 3)/220 (AC, FIG. 1/2).

The sensed current is transformed into a voltage representation usingthe sense resistor 152, and fed into controller 170 for further signalprocessing required to implement voltage/current regulation, powerprocessing efficiency improvements and over-current protection.

The preceding discussion provides many example embodiments. Althougheach embodiment represents a single combination of inventive elements,other examples may include all possible combinations of the disclosedelements. Thus if one embodiment comprises elements A, B, and C, and asecond embodiment comprises elements B and D, other remainingcombinations of A, B, C, or D, may also be used.

Although the embodiments have been described in detail, it should beunderstood that various changes, substitutions and alterations can bemade herein without departing from the scope as defined by the appendedclaims.

Moreover, the scope of the present application is not intended to belimited to the particular embodiments of the process, machine,manufacture, composition of matter, means, methods and steps describedin the specification. As one of ordinary skill in the art will readilyappreciate from the disclosure of the present invention, processes,machines, manufacture, compositions of matter, means, methods, or steps,presently existing or later to be developed, that perform substantiallythe same function or achieve substantially the same result as thecorresponding embodiments described herein may be utilized. Accordingly,the appended claims are intended to include within their scope suchprocesses, machines, manufacture, compositions of matter, means,methods, or steps

As can be understood, the examples described above and illustrated areintended to be exemplary only. The invention is defined by the claims.

What is claimed is:
 1. A flyback converter comprising: a capacitivedivider operatively connectable to a voltage source for receiving aninput voltage, the capacitive divider having a plurality of firstcapacitive devices connected in series with one another; a transformerhaving a plurality of primary transformer windings inductively coupledto at least one secondary transformer winding, each one of the primarytransformer windings of the transformer being connected in parallel to acorresponding one of the first capacitive devices of the capacitivedivider via a respective switch of a plurality of switches, each of theat least one secondary transformer winding being connected to acapacitive circuit operatively connectable to an output load; acontroller connected to each one of the plurality of switches foroperating the flyback converter to power the output load using thevoltage source; and a single first one of a snubber device, an activeclamp or a soft-switching circuit connected to a single first one of theplurality of primary transformer windings, a second one of the pluralityof primary transformer windings not being connected to any of a secondone of a snubber device, an active clamp and a soft-switching circuit.2. The flyback converter of claim 1, wherein: each switch of theplurality of switches comprises a body diode; and one or more of thebody diodes of the plurality of switches is operable to become forwardbiased, the one or more forward biased body diodes balancing dividedportions of the input voltage among the plurality of first capacitivedevices of the capacitive divider.
 3. The flyback converter of claim 1,further comprising: a current sensing circuit connected in parallelacross the capacitive divider for producing a current measurement bymeasuring an input current of the flyback converter and a currentthrough the plurality of switches, the current measurement beingutilized by the controller to regulate an output voltage of the flybackconverter.
 4. The flyback converter of claim 3, wherein: the currentmeasurement comprises a high-frequency component and a low-frequencycomponent, the high-frequency component being proportional to thecurrent through the plurality of switches, and the low-frequencycomponent being proportional to the input current of the flybackconverter.
 5. The flyback converter of claim 4, wherein: the currentsensing circuit comprises a series combination of a second capacitivedevice and a sense resistor.
 6. The flyback converter of claim 5,further comprising: an input filter operatively connected to the voltagesource, the flyback converter receiving the input voltage through theinput filter; wherein the second capacitive device is connected inparallel with the input filter.
 7. The flyback converter of claim 1,wherein: the controller is configured to operate each switch of theplurality of switches successively and repeatedly during normal use ofthe flyback converter.
 8. The flyback converter of claim 7, wherein:operation of the plurality of switches balances voltages across each oneof the first capacitive devices of the capacitive divider.
 9. Theflyback converter of claim 1, wherein: a first node of a first primarytransformer winding of the plurality of primary transformer windings isdirectly electrically connected to a first node of a first capacitor ofthe first capacitive devices; a second node of the first primarytransformer winding is directly electrically connected to a first nodeof a first switch of the plurality of switches; and a second node of thefirst switch is directly electrically connected to a second node of thefirst capacitor and to a first node of a second primary transformerwinding of the plurality of primary transformer windings.
 10. A methodfor operating a flyback converter that includes a transformer having aplurality of primary transformer windings each being connected inparallel with a corresponding first capacitive device of a capacitivedivider, the method comprising the steps of: receiving an input voltageat the capacitive divider; sequentially operating each one of theprimary transformer windings using a portion of the input voltage viathe corresponding first capacitive device, each of the primarytransformer windings being coupled to a corresponding one of the firstcapacitive devices by a respective switch of a plurality of switches;repeating the step of sequentially operating each one of the primarytransformer windings to generate an output voltage to an output load ofthe flyback converter; and limiting the portion of the input voltageassociated with a first one of the primary transformer windings, thelimiting being performed by a single first one of a snubber device, anactive damp, or a soft-switching circuit connected to the first one ofthe primary transformer windings, a second one of the primarytransformer windings not being connected to any of a second one of asnubber device, an active clamp and a soft-switching circuit.
 11. Themethod of claim 10, wherein: each of the primary transformer windings issequentially operated using the respective switch coupled to thatprimary transformer winding.
 12. The method of claim 11, wherein:operation of each of the primary transformer windings using therespective switches causes a balancing of the portion of the inputvoltage across each one of the first capacitive devices.
 13. The methodof claim 10, further comprising: producing, by a current sensingcircuit, a current measurement by measuring an input current of theflyback converter and current through the plurality of switches, thecurrent sensing circuit being connected in parallel with the capacitivedivider; and using the current measurement by a controller of theflyback converter to regulate the output voltage of the flybackconverter.
 14. The method of claim 13, wherein: the current measurementcomprises a high-frequency component and a low-frequency component, thehigh-frequency component being proportional to the current through theplurality of switches, and the low-frequency component beingproportional to the input current of the flyback converter.
 15. Themethod of claim 14, wherein: the current sensing circuit comprises aseries combination of a second capacitive device and a sense resistor,the series combination of the second capacitive device and the senseresistor being connected in parallel with the capacitive divider. 16.The method of claim 15, further comprising: providing the input voltageto the capacitive divider from an input filter operatively connectableto a voltage source, the second capacitive device being connected inparallel with the input filter.
 17. A flyback converter comprising: acapacitive divider operatively connected to a voltage source forreceiving an input voltage, the capacitive divider having a plurality offirst capacitive devices connected in series with one another to producea voltage drop across each one of the first capacitive devices; atransformer with a plurality of primary transformer windings, and asecondary output winding; a plurality of switches each for selectivelyinterconnecting one of the primary transformer windings with one of thefirst capacitive devices to drive a load connected to the secondaryoutput winding; a controller for operating the plurality of switchesbased on current through the plurality of switches; and a single firstone of a snubber device, an active clamp or a soft-switching circuitconnected to a single first one of the plurality of primary transformerwindings, a second one of the plurality of primary transformer windingsnot being connected to any of a second one of a snubber device, anactive clamp and a soft-switching circuit.
 18. The flyback converter ofclaim 17, further comprising: a current sensing circuit connected inparallel with the capacitive divider for producing a current measurementby measuring an input current of the flyback converter and the currentthrough the plurality of switches, the current measurement beingutilized by the controller to regulate an output voltage of the flybackconverter.
 19. The flyback converter of claim 18, wherein: the currentmeasurement comprises a high-frequency component and a low-frequencycomponent, the high-frequency component being proportional to thecurrent through the plurality of switches, and the low-frequencycomponent being proportional to the input current of the flybackconverter.
 20. The flyback converter of claim 18, wherein: the currentsensing circuit comprises a series combination of a second capacitivedevice and a sense resistor, the series combination of the secondcapacitive device and the sense resistor being connected in parallelwith the capacitive divider for measuring the input current of theflyback converter and the current through the plurality of switches.